Amalgamable composition and method of production

Abstract: A multi-component composition suitable for amalgamation with mercury to form a dental amalgam, an amalgam and a method for producing such a multi-component composition. The multi-component composition has: from 30 to 90% (by weight) of a first component containing at least 30% silver, at least 20% tin and at least 10% copper; from 10 to 70% (by weight) of a second component, or alternatively, from 5 to 65% (by weight) of a second component and from 5 to 65% (by weight) of a fourth component, the second and fourth components containing at least 30% silver, at least 20% tin and at least 10% copper; and up to 15% (by weight) of a third component containing silver and/or alloy powder containing at least 80% (by weight) silver. The first component is spherically shaped atomized alloy powder. The second component is mechanically worked atomized alloy powder. The surface area to volume ratio of the powder of the second component is greater than the surface area to volume ratio of the powder of the first component. The fourth component is irregularly shaped as atomized alloy powder.

Description: The present invention relates to a multi-component composition, and in particular, to a multi-component composition suitable for amalgamation with mercury to form a dental amalgam, to the amalgam formed therefrom, and to a method for producing such a multi-component composition. Amalgamable dental alloys are basically alloys of silver and tin with typical additions of copper and possible additions of other elements such as indium, zinc, and palladium. These alloys are supplied to dentists in particle form. Dentists add mercury to the alloy particles and triturate the mixture in an amalgamator to form an amalgamated mass which they, in turn, condense into cavities. Mercury reacts with silver and tin, forming compounds of silver-mercury and tin-mercury. The amount of mercury added by the dentist is not, however, sufficient to complete the reaction. As a result, mercury only reacts with the surface of the alloy particles. The core of the particle remains in the unreacted state. The amalgamated mass placed by a dentist in a cavity is, after hardening, therefore, a heterogeneous material of at least three distinct phases: silver-mercury; tin-mercury; and silver-tin. The phases are, respectively, for convenience purposes called gamma one, gamma two and gamma. When properties of the three phases are compared, it is found that strength and corrosion resistance are highest for the gamma phase and lowest for the gamma two phase. Relative ratios of these three phases, as well as the shape of the original alloy particles that are left in the final product, determine the physical properties of amalgamated dental alloys as well as their ease of manipulation. Alloy particles are typically spherical or irregular in shape. United States Patent No. 3,871,876 discloses an amalgamable alloy produced through gas atomization and, more particularly, particles of amalgamable alloy which are spherical in shape. The alloy of the patent is, on the one hand, known for smooth, strong and corrosion resistant dental restorations; and, on the other hand, for difficulties encountered in condensing it. Many dentists find that the spherical particles feel too soft and delicate to them insofar as the particles have a tendency to be forced up the sides of a cavity if too much pressure is exerted. An attempt to improve upon the alloy of Patent No. 3,871,876 is disclosed in United States Patent No. 3,997,329. Irregularly shaped particles are mixed with the spherical particles of Patent No. 3,871,876 to improve the condensing characteristics of the alloy. The irregular particles are typically lathe-cut. The addition of the lathe-cut particles of Patent No. 3,997,329 to the spherical particles of Patent No. 3,871,876 as taught in Patent No. 3,997,329 did, in fact, produce an alloy with better condensing characteristics. Unfortunately, certain disadvantages are associated with lathe-cut particles. Lathe-cut particles are characterized by a high percentage of oxides and other undesirable elements and by minute cracks. Their dirty surfaces can slow down a reaction with mercury when mercury is trapped in the cracks. This results in lower initial physical properties. Other patents disclosing dental alloys formed from mixtures of spherical particles and lathe-cut particles are United Sates Patent Nos. 3,997,327; 3,997,330; 4,234,339; and 4,664,629. Patent No. 4,664,629 discloses a composition which is taught in Patent No. 4,374,085. Through the present invention, there is provided an atomized multi-component composition, and a method for producing such, which upon amalgamation with mercury produces a dental amalgam having compressive strength, creep and condensation resistance comparable or better to that formed from the amalgamation of-dental alloys comprised of both spherical and lathe-cut particles, but yet a composition which is free of lathe-cut particles with their inherent disadvantages. There is also provided a multi-component composition which through the addition of a high silver alloy produces restorations characterized by reduced leakage. An attempt to produce an atomized composition with characteristics comparable to that of the present invention is disclosed in United States Patent Nos. 4,235,631 and 4,664,855. Although Patent No. 4,664,855 does disclose the addition of a high silver material to a dental composition, as does Japanese Patent Publication No. 58-56741, neither it nor Patent No. 4,235,631 discloses a composition containing spherical particles which significantly contribute to the strength of amalgam restorations. This is clearly evident from Patent No. 4,664,855 where the highest disclosed one hour compressive strength is 1827.8 kgf/cm 2 (26,000 pounds per square inch). It is accordingly an object of the present invention to provide a multi-component composition suitable for amalgamation with mercury to form a dental amalgam. It is accordingly a further object of the present invention to provide an amalgam formed upon amalgamation of the multi-component composition of the present invention. It is accordingly a still further object of the present invention to provide a method for producing a multi-component composition suitable for amalgamation with mercury to form a dental amalgam. The present invention provides a multi-component composition suitable for amalgamation with mercury to form a dental material. More specifically, a multi-component composition having up to three distinct components in accordance with claim 1 of the appended claims, and in a specific embodiment, up to four distinct components in accordance with claim 2 of the appended claims. The invention further provides an amalgam in accordance with claims 9 and 10 of the appended claims. Particles of the first component are substantially spherical in shape. At least 40%, by weight, of the multi-component composition is of these particles. They provide strength and corrosion resistance, and facilitate carving. On the other hand, no more than 75%, by weight, of the composition is of these particles. They tend to make it more difficult to condense the composition. These particles are present in an amount of from 40 to 75%. The word spherical, as used herein, is meant to include particles which are spherical in shape as well as those which are spherical in shape with other spherical particles adhered to them. Particles of the second component are mechanically worked to increase the surface area to volume ratio of the particles. The surface area to volume ratio of the particles of the second component is greater than the surface area to volume ratio of the particles of the first component. At least 25%, by weight, of the multi-component composition is of these particles. They provide for better adaption of an amalgam to a cavity and facilitate condensing of the composition. On the other hand, no more than 55%, by weight, of the composition is of these particles. Strength and corrosion resistance decrease and carved surfaces are rougher (thereby increasing the tendency for plaque formation) with increasing percentages. In most instances, these particles are present in an amount of from 25 to 55%. The particles of both the first and second components are alloys of silver, tin and copper. They typically contain, by weight, at least 30% silver, at least 20% tin and at least 10% copper. More specifically, they contain from 30 to 70% silver, 20 to 35% tin, 10 to 40% copper, up to 2% noble metal (palladium, platinum, gold, ruthenium, rhodium, osmium, iridium), up to 4% zinc, up to 6% indium, up to 5% manganese, up to 2% aluminum, up to 5% gallium, and up to 3% mercury. The specific chemistry of the first component may be the same as or dissimilar to that of the second component. Each of the first and second components should be, in and by itself, free or substantially free of a tendency to form gamma two phase. Copper is preferably maintained at levels below 25 % as copper has a tendency to darken restorations. Particles of the third component are present in an amount of up to 15%, by weight, and generally in an amount of from 2 to 12%. The particles are either pure silver and/or an alloy containing at least 80% silver, by weight; e.g., an alloy of silver and one or more of tin, zinc, copper, indium, palladium, magnesium, mercury, platinum, gold, osmium, rhodium, ruthenium, rhenium and iridium. Alloys of silver and tin or silver and zinc are especially preferred. Sufficient silver must be present to form enough gamma one phase to substantially overcome the shrinkage caused by the first and second components. This will, in turn, lessen leakage. Post operative sensitivity and possible reoccurrence of decay are attributable to leakage. Irregular as atomized particles (particles which have not been mechanically worked) having an average length to average width ratio of at least 1.5 may replace a portion of the particles of the second component. These particles, herein-after referred to as the fourth component, have been found to be more effective in enhancing condensing characteristics than are the particles of the second component. They are, when present, present in an amount of from 5 to 65%. Particles of the second component are also present in an amount of from 5 to 65% when particles of the fourth component are present. The presence of fourth component particles must, however, be controlled as carvability and amalgam surface texture deteriorate with increasing percentages of the fourth component. Increasing percentages of the fourth component are accompanied by rougher surfaces, thereby increasing the tendency for plaque to form. Particles of the second and fourth component are present in cumulative amounts of from 25 to 55%. The particles of the fourth component are, like the particles of the second component, alloys of silver, tin and copper. They typically contain, by weight, at least 30% silver, at least 20% tin and at least 10% copper. More specifically, they contain from 30 to 70% silver, 20 to 35% tin, 10 to 40% copper, up to 2% noble metal (palladium, platinum, gold, ruthenium, rhodium, osmium, iridium), up to 4% zinc, up to 6% indium, up to 5% manganese, up to 2% alumimum, up to 5% gallium, and up to 3% mercury. The specific chemistry of the fourth component may be the same as or dissimilar to that of the second component. The fourth component should, moreover, be free or substantially free of a tendency to form gamma two phase. Copper is preferably maintained at levels below 25% as copper has a tendency to darken restorations. The amalgam of the present invention is generally characterized by a one hour compressive strength of at least 2038.7kgf/cm 2 (29,000) and preferably 2179.3kgf/cm 2 (31,000 pounds per square inch), in those instances where the multi-component composition does not contain irregular as atomized particles and at least 1898.1kgf/cm 2 (27,000 pounds per square inch)in those instances where the multi-component composition does contain irregular as atomized particles. All other factors being the same, compressive strength is somewhat compromised by the inclusion of irregular as atomized particles in the multi-component composition. Amalgams are formed by triturating from 30 to 56% of mercury with from 44 to 70% of the multi-component composition of the present invention. Triturating is performed in accordance with procedures well known to those skilled in the art. Mercury is usually present in amounts of from 37 to 50%. The invention further provides a method in acordance with claim 17 of the appended claims. The multi-component composition of the present invention is produced in accordance with the following steps: producing a melt of a first component containing, by weight, at least 30% silver, at least 20% tin and at least 10% copper; atomizing the melt of the first component, thereby forming particles of the first component; collecting the particles of the first component; heat treating the particles of the first component to obtain desired working time; producing a melt of a second component containing, by weight, at least 30% silver, at least 20% tin and at least 10% copper; atomizing the melt of the second component thereby forming particles of the second component; collecting the particles of the second component; mechanically working the particles of the second component so as to increase the surface area to volume ratio of the particles; heat treating the particles of the second component to obtain desired working time; optionally providing particles of a third component of silver or an alloy containing at least 80%, by weight, of silver; heat treating, if necessary or desirable, the particles of the third component to obtain desired working time; and blending the particles of the first component with the particles of the second component and the particles of the third component so as produce a multi-component composition containing from 40 to 75%, by weight, of the first component, from 25 to 55%, by weight, of the second component and up to 15%, by weight, of the third component. The first and second component can be atomized in any manner known to those skilled in the art, providing that in the case of the first component, spherical particles are produced. These means include gas atomization, water atomization and spinning disc atomization. Gas atomization of the first component is preferred. Typical gas atomizing mediums are argon and nitrogen. The gas atomized powder can be dry or wet collected. The third component is preferably, but not necessarily, atomized. Various means for mechanically working the second component are also known to those skilled in the art. These means include hammer mills, rod mills and ball mills. Ball milling for at least thirty minutes is generally called for. Times in excess of one hour are preferred. Working times cannot, however, be precisely set forth as they are dependent upon various factors including the nature of the material being worked and the type of apparatus being used. A protective atmosphere may be employed during mechanical working. Should a two component composition be desired, in contrast to that discussed in the preceding section, the steps pertaining to the third component are eliminated. A multi-component composition with all three components is, nevertheless, a preferred embodiment of the present invention. The following additional steps are followed in those instances where a composition containing the fourth component is desired: producing a melt of a fourth component containing, by weight, at least 30% silver, at least 20% tin and at least 10% copper; atomizing the melt of the fourth component, thereby forming particles of the fourth component; collecting the particles of the fourth component; heat treating the particles of the fourth component to obtain desired working time; and blending the particles of the fourth component with the particles of the first and second components and, possibly with the particles of the third component, so as to produce a multicomponent composition containing from 30 to 90%, by weight, of the first component, from 5 to 65%, by weight, of the second component, up to 15%, by weight, of the third component and from 5 to 65 %, by weight, of the fourth component. The fourth component is, preferably, water atomized. The heat treatment of the particles comprises heating the particles to a temperature of between 150 and 800°F (83 to 444°C) for a period of between 30 minutes and 8 hours. The following examples are illustrative of several aspects of the invention. Example 1 Three two-component compositions (Compositions A, B and C) were prepared. The overall chemistry of the compositions was very similar. Each of the compositions contained approximately 50% silver, 20% copper and 30% tin, with a palladium addition of less than 0.55%. The make-up of the compositions appears hereinbelow in Table I. COMPOSITION A. 60% gas atomized spherical particles 40% lathe cut particles B. 60% gas atomized spherical particles 40% ball milled, gas atomized particles C. 60% gas atomized spherical particles 40% ball milled, water atomized particles Composition B was ball milled for one hour. Composition C was ball milled for two hours. All of the gas atomized particles were wet collected. Each composition was heat treated to produce a "short" and a "long" carve time, and amalgamated with from 43 to 48% mercury. Carve time is the period from amalgamation to the time when the material will chip rather than cut or carve smoothly. The compositions with the "short" carve time are identified as A 1 , B 1 and C 1 . The compositions with the "long" carve time are identified as A 2 , B 2 and C 2 . The carve times appear hereinbelow in Table II. COMPOSITION CARVE TIME (minutes) A 1 5.75 B 1 6.25 C 1 6.0 A 2 7.5 B 2 8.25 C 2 8.25 Compositions A 1 , B 1 and C 1 were tested for compressive strength (1 hour and 24 hour), creep (24 hour) and condensation resistance. The results of the tests appear hereinbelow in Table III. COMPOSITION COMPRESSIVE STRENGTH kgf/cm 2 (pounds per square inch) CONDENSATION RESISTANCE (millimeters) 1 HOUR 24 HOURS CREEP (%) A 1 1898.1 (27,000) 4288.3 (61,000) 0.08 0.5 B 1 3233.8 (46,000) 5483.4 (78,000) 0.03 0.7 C 1 2319.9 (33,000) 4991.3 (71,000) 0.05 0.6 Compositions B 1 and C 1 displayed superior compressive strength to Composition A 1 , and creep and condensation resistance comparable thereto. This is most significant insofar as Compositions B 1 and C 1 do not contain lathe-cut particles with their inherent disadvantages as discussed hereinabove. Compositions A 2 , B 2 and C 2 were tested for compressive strength (1 hour and 24 hour), creep (24 hour) and condensation resistance. The results of the tests appear hereinbelow in Table IV. COMPOSITION COMPRESSIVE STRENGTH kgf/cm 2 (pounds per square inch) CONDENSATION RESISTANCE (millimeters) 1 HOUR 24 HOURS CREEP (%) A 2 1827.8 (26,000) 4499.2 (64,000) N.A. 0.7 B 2 2882.3 (41,000) 5272.5 (75,000) 0.04 0.7 C 2 2390.2 (34,000) 5272.5 (75,000) 0.06 0.6 Compositions B 2 and C 2 displayed superior compressive strength to Composition A 2 , and condensation resistance comparable thereto. This is, again, most significant insofar as Compositions B 2 and C 2 do not contain lathe-cut particles with their inherent disadvantages as discussed hereinabove. Condensation resistance measurements were made in accordance with the test (modified by subtracting the original height) described in an article entitled, "Measurement of Resistance of Amalgam Mixes to Condensation." The article authored by H. Ogura, F. Hadavi and K. Asgar appeared in the August, 1983 issue of the Journal of Dental Research. Example II. Compositions D 1 , E 1 and E 2 were amalgamated with from 43 to 48% mercury and tested for condensation resistance. The overall chemistries of these compositions were very similar to those of Compositions A, B and C. Compositions D 1 , E 1 and E 2 were 100% gas atomized. None of these compositions were ball milled. Composition D 1 was wet collected. Compositions E 1 and E 2 were dry collected. The carve times for Compositions D 1 , E 1 and E 2 were respectively 6, 6 and 7.5 minutes. The condensation resistance for each appears hereinbelow in Table V. COMPOSITION CONDENSATION RESISTANCE (millimeters) D 1 1.4 E 1 1.0 E 2 1.4 Note that the condensation resistance for Compositions D 1 , E 1 and E 2 is significantly less (lower numbers indicate greater resistance) than that for Compositions B 1 , B 2 , C 1 and C 2 . This is very significant, especially with respect to Compositions B 1 and D 1 , since the only significant difference between Compositions B 1 and D 1 is the fact that a portion of Composition B 1 was ball milled. Example III. Compositions B 1 , B 2 , C 1 and C 2 were modified to include 8% of a high silver alloy (95% silver, 5% tin). The newly created compositions were identified as F 1 , F 2 , G 1 and G 2 . Compositions F 1 , F 2 , G 1 and G 2 respectively corresponded to modified versions of Compositions B 1 , B 2 , C 1 and C 2 . The carve times for Compositions F 1 , F 2 , G 1 and G 2 after amalgamation with from 43 to 48% mercury, appear hereinbelow in Table VI. COMPOSITION CARVE TIME (minutes) F 1 5.75 G 1 5.5 F 2 7.75 G 2 6.5 Compositions B 1 , B 2 , C 1 , C 2 , F 1 , F 2 , G 1 and G 2 were tested for dimensional change (24 hour) and leakage at 20 psig. The results of the tests appear hereinbelow in Table VII. COMPOSITION DIMENSIONAL CHANGE (mm per centimeter) LEAKAGE (milliliters per minute) B 1 -1.1 2.0 B 2 -3.4 3.1 C 1 -2.5 1.9 C 2 -2.9 2.6 F 1 2.45 1.2 F 2 1.7 0.9 G 1 1.5 0.6 G 2 1.2 0.4 Compositions F 1 , F 2 , G 1 and G 2 , with the high silver alloy addition, expanded whereas Compositions B 1 , B 2 , C 1 and C 2 , which did not have the high silver addition, contracted. Leakage, most notably, was significantly lower for Compositions F 1 , F 2 , G 1 and G 2 than for Compositions B 1 , B 2 , C 1 and C 2 . Post operative sensitivity and possible reoccurrence of decay are attributable to leakage. Leakage measurements were made in accordance with the test described in an article entitled, "Marginal Leakage of Dental Amalgam." The article authored by F. Fanian, F. Hadavi and K. Asgar appeared in the August 11, 1983 issue of Operative Dentistry. Compositions F 1 and F 2 were tested for compressive strength (1 hour and 24 hour), creep (24 hour) and condensation tion resistance. The results of the tests appear hereinbelow in Table VIII. COMPOSITION COMPRESSIVE STRENGTH kgf/cm 2 (pounds per square inch) CONDENSATION RESISTANCE (millimeters) 1 HOUR 24 HOURS CREEP (%) F 1 2952.6 (42,000) 4921 (70,000) 0.05 0.6 F 2 2319.9 (33,000) 5131.9 (73,000) 0.04 0.7 Compositions F 1 and F 2 displayed superior compressive strength to Compositions A 1 and A 2 (Example I), and creep and condensation resistance comparable thereto. This is most significant insofar as Compositions F 1 and F 2 do not contain lathe-cut particles with their inherent disadvantages as discussed hereinabove. Example IV. One three-component composition (Composition H) and one four-component composition (Composition I) were prepared. The overall chemistry of the compositions was very similar. Each of the compositions contained approximately 50% silver, 20% copper and 30% tin, modified to include 10% of a high silver alloy (95% silver, 5% tin). The make-up of the compositions appears hereinbelow in Table IX. COMPOSITION H. 50% gas atomized spherical particles 40% ball milled, gas atomized particles 10% high silver alloy I. 50% gas atomized spherical particles 10% ball milled, gas atomized particles 10% high silver alloy 30% water atomized irregular particles Compositions H and I were ball milled for five hours. The gas atomised particles were dry collected. Each composition was heat treated to produce a carve time of 8 minutes. The compositions were amalgamated with from 44 to 48% mercury. Compositions H and I were tested for one hour compressive strength and condensation resistance. The results of the tests appear hereinafter in Table X. COMPOSITION COMPRESSIVE STRENGTH kgf/cm 2 (pounds per square inch) CONDENSATION RESISTANCE (millimeters) 1 HOUR H 2319.9 (33,000) 0.90 I 1968.4 (28,000) 0.35 Composition I (the four-component composition) displayed superior condensation resistance to Composition H (the three-component composition). This is significant as the only marked difference between Compositions H and I is the replacement of a portion of the milled particles of H with the irregular as atomized particles of I. As stated hereinabove, Applicants have found that irregular as atomized particles (the fourth component) are more effective in enhancing condensing characteristics than are mechanically worked, gas atomized particles (the second component). Condensation resistance measurements were made as discussed in Example I. As stated hereinabove, lower numbers indicate greater resistance. It will be apparent to those skilled in the art that the novel principles of the invention disclosed herein in connection with specific examples thereof will suggest various other modifications and applications of the same. It is accordingly desired that in construing the breadth of the appended claims they shall not be limited to the specific examples of the invention described herein.

Claims: A multi-component composition suitable for amalgamation with mercury to form a dental material, comprising: (a) from 40 to 75 %, by weight, of a first alloy powder component containing, by weight, at least 30 % silver, at least 20 % tin and at least 10% copper; (b) from 25 to 55%, by weight, of a second alloy powder component containing, by weight, at least 30% silver, at least 20% tin and at least 10% copper; and (c) up to 15%, by weight, of a third component comprising silver or an alloy powder containing at least 80%, by weight, of silver, wherein said first component is atomized alloy powder, wherein said alloy powder of said first component comprises particles which are substantially spherical in shape and wherein said second component is atomized alloy powder which has been mechanically worked to increase the surface area to volume ratio of its particles, the surface area to volume ratio of the particles of said alloy of said second component being greater than the surface area to volume ratio of the particles of said alloy of said first component. A multi-component composition suitable for amalgamation with mercury to form a dental material, comprising: (a) from 40 to 75%, by weight, of a first alloy powder component containing, by weight, at least 30% silver, at least 20% tin and at least 10% copper; (b) from 5 to 65%, by weight, of a second alloy powder component containing, by weight, at least 30 % silver, at least 20 % tin and at least 10% copper; (c) up to 15%, by weight, of a third component comprising silver or an alloy powder containing at least 80%, by weight, of silver; and (d) from 5 to 65%, by weight, of a fourth component, an alloy powder containing, by weight, at least 30 % silver, at least 20 % tin and at least 10% copper, wherein said first component is atomized alloy powder, wherein said alloy powder of said first component comprises particles which are substantially spherical in shape, wherein said second component is atomized alloy powder which has been mechanically worked to increase the surface area to volume ratio of its particles, the surface area to volume ratio of the particles of said alloy of said second component being greater than the surface area to volume ratio of the particles of said alloy of said first component, wherein said fourth component is atomized alloy powder, wherein said alloy powder of said fourth component comprises particles which are as atomized substantially irregular in shape, the average length to average width ratio of said irregular particles being at least 1.5 and wherein said second and fourth components are present, by weight, in a cumulative amount of from 25 to 55 %. A composition according to claim 1 or claim 2, wherein said third component is present, by weight, in an amount from 2 to 12 %. A composition according to any one of the preceding claims, wherein said alloy powder of said first component comprises, by weight, 30 to 70% silver, 20 to 35% tin, 10 to 40% copper, up to 2% noble metal, up to 4% zinc, up to 6% indium, up to 5% manganese, up to 2% aluminum, up to 5 % gallium and up to 3 % mercury. A composition according to any one of the preceding claims, wherein said alloy powder of said second component comprises, by weight, 30 to 70% silver, 20 to 35% tin, 10 to 40% copper, up to 2% noble metal, up to 4% zinc, up to 6% indium, up to 5% manganese, up to 2% aluminum, up to 5% gallium and up to 3% mercury. A composition according to claim 2 or any one of claims 3 to 5 when dependent on claim 2, wherein said alloy powder of said fourth component comprises, by weight, 30 to 70% silver, 20 to 35 % tin, 10 to 40 % copper, up to 2 % noble metal, up to 4 % zinc, up to 6% indium, up to 5% manganese, up to 2% aluminum, up to 5% gallium and up to 3% mercury. A composition according to Claim 1, capable of forming a dental amalgam having a one hour compressive strength of at least 2038 kgf/cm 2 (29,000 pounds per square inch). A composition according to Claim 2, capable of forming a dental amalgam having a one hour compressive strength of at least 1898.1 kgf/cm 2 (27,000 pounds per square inch). An amalgam formed from 30 to 56% of mercury and from 44 to 70 % of a multi-component composition; said multi-component composition comprising: (a) from 40 to 75%, by weight, of a first alloy powder component containing, by weight, at least 30 % silver, at least 20 % tin and at least 10% copper; (b) from 25 to 55%, by weight, of a second alloy powder component containing, by weight, at least 30% silver, at least 20% tin and at least 10% copper; and (c) up to 15%, by weight, of a third component comprising silver or an alloy powder containing at least 80%, by weight, of silver, wherein said first component is atomized alloy powder, wherein said alloy powder of said first component comprises particles which are substantially spherical in shape and wherein said second component is atomized alloy powder which has been mechanically worked to increase the surface area to volume ratio of its particles, the surface area to volume ratio of the particles of said alloy of said second component being greater than the surface area to volume ratio of the particles of said alloy of said first component. An amalgam formed from 30 to 56% of mercury and from 44 to 70% of a multi-component composition; said multi-component composition, comprising: (a) from 40 to 75%, by weight, of a first alloy powder component containing, by weight, at least 30% silver, at least 20% tin and at least 10% copper; (b) from 5 to 65%, by weight, of a second alloy powder component containing, by weight, at least 30 % silver, at least 20 % tin and at least 10% copper; (c) up to 15%, by weight, of a third component comprising silver or an alloy powder containing at least 80%, by weight, of silver; and (d) from 5 to 65%, by weight, of a fourth component, an alloy powder containing, by weight, at least 30% silver, at least 20% tin and at least 10% copper, wherein said first component is atomized alloy powder, wherein said alloy powder of said first component comprises particles which are substantially spherical in shape, wherein said second component is atomized alloy powder which has been mechanically worked to increase the surface area to volume ratio of its particles, the surface area to volume ratio of the particles of said alloy of said second component being greater than the surface area to volume ratio of the particles of said alloy of said first component, wherein said fourth component is atomized alloy powder, wherein said alloy powder of said fourth component comprises particles which are as atomized substantially irregular in shape, the average length to average width ratio of said irregular particles being at least 1.5 and wherein said multi-component composition has a cumulative amount of from 25 to 55% of said second and fourth components. An amalgam according to Claim 9 or Claim 10, formed from mercury and a multi-component composition, wherein said multi-component composition has from 2 to 12% of said third component. An amalgam according to any one of Claims 9 to 11, formed from mercury and a multi-component composition, wherein said first component of said multi-component composition comprises, by weight, 30 to 70% silver, 20 to 35% tin, 10 to 40% copper, up to 2% noble metal, up to 4% zinc, up to 6% indium, up to 5% manganese, up to 2% aluminum, up to 5 % gallium and up to 3 % mercury. An amalgam according to any one of Claims 9 to 12, formed from mercury and a multi-component composition, wherein said second component of said multi-component composition comprises, by weight, 30 to 70 % silver, 20 to 35 % tin, 10 to 40 % copper, up to 2 % noble metal, up to 4% zinc, up to 6% indium, up to 5% manganese, up to 2% aluminum, up to 5 % gallium and up to 3 % mercury. An amalgam according to any one of Claims 9 to 13, formed from mercury and a multi-component composition, wherein said fourth component of said multi-component composition comprises, by weight, 30 to 70% silver, 20 to 35% tin, 10 to 40% copper, up to 2% noble metal, up to 4% zinc, up to 6% indium, up to 5% manganese, up to 2% aluminum, up to 5% gallium and up to 3% mercury. An amalgam according to Claim 9, formed from mercury and a multi-component composition, wherein said amalgam has a one hour compressive strength of at least 2038 kgf/cm 2 (29,000 pounds per square inch). An amalgam according to Claim 10, formed from mercury and a multi-component composition, wherein said amalgam has a one hour compressive strength of at least 1898.1 kgf/cm 2 (27,000 pounds per square inch). A method for producing a multi-component composition suitable for amalgamation with mercury to form a dental material, which method comprises the steps of: producing a melt of a first component containing, by weight, at least 30% silver, at least 20% tin and at least 10% copper; atomizing said melt of said first component, thereby forming particles of said first component; collecting said particles of said first component; heat treating the particles of said first component thereby obtaining a desired carve time; producing a melt of a second component containing, by weight, at least 30% silver, at least 20% tin and at least 10% copper; atomizing said melt of said second component thereby forming particles of said second component; collecting said particles of said second component; mechanically working said particles of said second component so as to increase the surface area to volume ratio of the particles of the second component, the surface area to volume ratio of the worked particles of the second component being greater than the surface area to volume ratio of the particles of the first component; heat treating the particles of said second component thereby obtaining a desired carve time; and blending said particles of said first component with said particles of said second component so as to produce a multi-component composition containing from 40 to 75%, by weight, of said first component and from 25 to 55%, by weight, of said second component. A method according to Claim 17, wherein said particles of said second component are mechanically worked by ball milling for at least thirty minutes. A method according to Claim 18, wherein said particles of said second component are mechanically worked by ball milling for at least one hour. A method according to any one of Claims 17 to 19, further comprising the steps of: providing particles of a third component comprising silver or an alloy powder containing at least 80%, by weight, silver; and blending said particles of said first component with said particles of said second component and said particles of said third component so as to produce a multi-component composition containing from 40 to 75%, by weight, of said first component, from 25 to 55 %, by weight, of said second component and up to 15 %, by weight, of said third component. A method according to any one of Claims 17 to 20 further comprising the steps of: producing a melt of a fourth component containing, by weight, at least 30% silver, at least 20% tin and at least 10% copper; atomizing the melt of the fourth component, thereby forming particles of the fourth component; collecting the particles of the fourth component; heat treating the particles of the fourth component to obtain desired working time; and blending the particles of the fourth component with the particles of the first and second components, and with the particles of the third component if used, so as to produce a multi-component composition containing from 40 to 75 %, by weight, of the first component, from 5 to 65%, by weight, of the second component, up to 15 % by weight of the third component and from 5 to 65 % by weight of the fourth component, and wherein said multi-component composition has a cumulative amount of from 25 to 55% of said second and fourth components.

Inventors: ASGAR KAMAL, FOUNTAIN RICHARD W, ASGAR, KAMAL, FOUNTAIN, RICHARD W.
Applicants: SPECIAL METALS CORP, SPECIAL METALS CORPORATION
Application year: 1994
Main classification: A61K6
IPC codes: C22C7, C22C1, A61K6